Filter cartridge placement in filter as you pour system

ABSTRACT

In one example, a fluid container includes a reservoir that includes a reservoir wall. A cover is configured to engage the reservoir, and the cover includes a spout configured and arranged for fluid communication with the reservoir, and the spout is disposed at one end of the cover. The fluid container also includes a filter cage configured to releasably engage the cover in a location near the spout. When the filter cage is engaged with the cover, and the cover is disposed on the reservoir, a small gap is defined between the front of the spout and the front of the filter cage.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 15/756,809 filed on Mar. 1, 2018, now U.S. Pat. No. 10,343,931, which claims the benefit and priority of International Application No. PCT/IB2016/001474 filed on Sep. 27, 2016, which claims the benefit of U.S. Provisional Application No. 62/235,321 filed on Sep. 30, 2015. This application is also related to the following United States Patent Applications: (1.) U.S. application Ser. No. 15/756,713 filed on Mar. 1, 2018, which claims the benefit and priority of International Application No. PCT/IB2016/001472, filed on Sep. 27, 2016, which claims the benefit of U.S. Provisional Application No. 62/235,289, filed on Sep. 30, 2015; (2.) U.S. application Ser. No. 15/756,747 filed on Mar. 1, 2018, which claims the benefit and priority of International Application No. PCT/IB2016/001495, filed on Sep. 27, 2016, which claims the benefit of U.S. Provisional Application No. 62/235,295, filed on Sep. 30, 2015; and (3.) U.S. application Ser. No. 15/756,768 filed on Mar. 1, 2018, which claims the benefit and priority of International Application No. PCT/IB2016/001479, filed on Sep. 27, 2016, which claims the benefit of U.S. Provisional Application No. 62/235,304, filed on Sep. 30, 2015. The entire disclosures of each of the above applications are incorporated herein by reference.

FIELD

Embodiments of the present invention generally concern water filtration systems for pitchers and other fluid containers. More particularly, embodiments of the invention relate to the placement of a filter core cartridge in a fluid container. At least some embodiments can be employed in a filter-as-you-pour (FAYP) system.

BACKGROUND

Water filtration has become common in homes, offices and other places to produce cleaner and better tasting water. Accordingly, water containers such as pitchers have been equipped with filtration systems. In some instances, these filtration systems may employ a filter core through which water passes as a reservoir of the water container is filled. The filtered water than can be dispensed from the reservoir. This design approach has proven problematic however and attention has accordingly shifted to other designs, such as filter-as-you-pour (FAYP) configurations.

In general, FAYP devices are configured with a reservoir that holds a volume of unfiltered fluid. The fluid passes through the filter as it is dispensed from the reservoir. This configuration is an improvement on earlier designs in some respects, but at least some FAYP devices nonetheless present some problems.

For example, some FAYP devices are configured in such a way that a significant amount of fluid in the reservoir can bypass the filter as the fluid is dispensed from the reservoir. This can occur because the fluid pathway between the filter and the outlet of the reservoir is not closed, or at least is not substantially closed. This fluid pathway configuration can arise due to the placement of the filter in the reservoir. In particular, the filter may be located in a location in the reservoir that is spaced well away from the outlet, such as about midway between opposing walls of the reservoir. Because the fluid pathway between the filter and the outlet is not closed, fluid from the reservoir can readily bypass the filter and exit the reservoir.

This problem can be appreciated by considering a substantially full fluid container disposed in a nearly horizontal dispensing position, where the filter is located approximately midway between opposing walls of the reservoir, and where the outlet of the reservoir is located on or near the lowermost wall of the reservoir. Thus, the walls of the reservoir and the filter are all generally horizontal in their orientation. In this circumstance, about half or more of the fluid in the reservoir resides in the space between the filter and the outlet and thus can readily pass through the outlet without first passing through the filter. Moreover, while fluid located in the space between the uppermost wall of the reservoir and the filter may possibly pass through the filter prior to exiting through the outlet, the open path between the filter and the outlet allows the possibility that filtered water can mix with unfiltered water prior to being dispensed from the reservoir.

This problem may become more acute in circumstances where the reservoir is less than full. For example, and depending upon the fullness of the reservoir, it may be the case that when the reservoir is tipped to a nearly horizontal, or other, dispensing position, all or nearly all of the fluid in the reservoir resides in the space between the filter and the outlet and thus can readily pass through the outlet without first passing through the filter. In this circumstance, little or no filtration occurs as fluid is dispensed from the reservoir. As with the other problems noted above, such result leads to a poor experience for the consumer.

A related problem concerns the fluid resistance offered by the filter. The filter, by its nature, tends to provide some resistance to flow through the filter. Thus, from this perspective at least, the filter can be considered to act as a flow restrictor. However, the fluid in the reservoir will tend to follow the path of least resistance when exiting the reservoir and as such, that fluid will tend to pass around the filter rather than through the filter.

Finally, the location of the filter and the fluid resistance offered by the filter have at least one other unfavorable implication. In particular, and with reference again to the example circumstance where a substantially full fluid container is in a generally horizontal position, the filter may be located about mid-depth in the fluid. Because the hydrostatic pressure of the fluid varies from a maximum at the bottom of the fluid to a minimum at the surface of the fluid, the hydrostatic pressure of the fluid just above the filter is significantly less than the maximum hydrostatic pressure. As a result, the flow rate through the filter, which is a function of the hydrostatic pressure of the fluid above the filter, is significantly compromised.

In light of problems such as those noted above, it would be useful to provide a fluid container configured to define a closed, or substantially closed, fluid pathway between a filter and a reservoir outlet. Further, it would be useful to provide a fluid container configured to implement any one or more of reduction or minimization of the amount of unfiltered water left in the fluid container after a dispensing event, reduction or substantial elimination of bypass around the filter, and achievement of relatively higher flow rates based on hydrostatic pressure at the filter. As well, it would be useful to provide a fluid container configured such that the filter is located relatively close to the outlet of the container. Finally, it would be useful to provide a fluid container configured to enable placement of a filter relatively close to the side of the fluid container where the outlet is located. Any of the aforementioned containers could take the form of a filter-as-you-pour container.

SUMMARY

One or more embodiments within the scope of the invention may be effective in overcoming one or more of the disadvantages in the art, although it is not required that any embodiment resolve any particular problem(s). One example embodiment is directed to a filter-as-you-pour (FAYP) fluid container having a filter and spout configured and arranged such that a fluid pathway between the filter and the spout is closed, or substantially closed. The filter resides in a cage that is removably attached to a lid or other portion of the fluid container. As well, the fluid container includes a reservoir configured and arranged such that the filter is disposed in the reservoir and located relatively close to the wall of the reservoir. In one particular embodiment, the filter is oriented to be generally parallel to the wall, which may be non-vertical, and is arranged such that there is a gap between the front edge of the spout and the front edge of the filter cage whose width is in the range of about 2.0 mm to about 20 mm.

In this example, the filter includes a filter core that is configured and arranged so that a filter medium, which may take the form of a laminate, is securely attached to the filter core without the use of glue. One example of such a filter medium is a laminate that includes a layer of activated carbon fiber (ACF) media positioned between two layers of non-woven material which are arranged so that when the laminate is wrapped around the filter core, one of the non-woven layers is an inner layer, and the other non-woven layer is an outer layer. Each side of the non-woven layers may include an adhesive layer or adhesive material so that the non-woven layers can achieve and maintain substantial contact with the ACF layer, and with each other.

The foregoing embodiment is provided solely by way of example and is not intended to limit the scope of the invention in any way. Consistently, various other embodiments of fluid containers, filter assemblies, and associated filter medium and filter cores, within the scope of the invention are disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which at least some aspects of this disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only example embodiments of the invention and are not therefore to be considered to be limiting of its scope, embodiments of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

FIG. 1 is a top perspective view of an example embodiment of a fluid container;

FIG. 2 is a bottom perspective view of an example embodiment of a filter assembly and associated cage attached to a lid;

FIG. 3 is an exploded view of the example of FIG. 2;

FIG. 4 is a partial exploded section view of an example filter and associated cage including a flow regulator; and

FIG. 5 is a partial section view showing the arrangement of an example filter and cage with respect to a reservoir wall of a fluid container.

DETAILED DESCRIPTION OF DRAWINGS

Reference will now be made in detail to aspects of various embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. While described in conjunction with these embodiments, it will be understood that they are not intended to limit the disclosure to these embodiments.

In general, embodiments of the invention can be employed in connection with devices, such as fluid containers, where there is a need to filter fluid as the fluid is dispensed from the container. In one particular example, embodiments of the invention can be used in conjunction with a pitcher, although the scope of the invention is not limited to this example environment and extends, more generally, to any environment where such embodiments can be usefully employed. For example, embodiments of the invention can be employed with any water, or other fluid, container, examples of which include, but are not limited to, bottles, carafes, and jugs.

A. Example Fluid Container

Directing attention now to FIG. 1, details are provided concerning a fluid container, one example of which is denoted generally at 100. In at least some embodiments, the fluid container 100 has a filter-as-you-pour configuration in which unfiltered fluid, such as unfiltered water for example, passes through a filter during a fluid dispensing process.

In general, the fluid container 100 can include a reservoir 102 having a wall 102 a that may be substantially formed as a unified single-piece structure. A handle 104 attached to the reservoir 102 enables a user to readily pick up the fluid container 100 and dispense fluid from the reservoir 102. The fluid container 100 further includes a removable cover 106 that fits onto, and substantially covers, the top of the reservoir 102. The cover 106 is rotatably connected to the handle 104 by a hinge 108.

The cover 106 includes a lid 110 that is rotatably connected to the body of the cover 106 and that covers a fill opening 106 a of the cover 106. The lid 110 can include electronics 112, such as visual indicators, accelerometers, counters and/or other electronic devices that can perform functions such as tracking the number of times that the lid 110 has been opened, such as in connection with a fill operation for example, and indicating to a user when a filter (see, e.g., FIGS. 2-5) should be replaced. Finally, the cover 106 includes a spout 114, or other outlet, that is configured and arranged for fluid communication with the interior of the reservoir 102 so that fluid in the reservoir 102 can exit the fluid container 100 by way of the spout 114.

B. Example Filter Assembly and Filter Cage

Directing attention now to FIGS. 2-4, details are provided concerning some example filter assemblies and filter cages. With reference first to FIG. 2, an example filter cage is denoted at 200, and a filter assembly denoted at 300 is removably positioned in the filter cage 200. In general, and as shown in FIG. 2, the filter cage 200 can be attached to the underside of the cover 106. More particularly, the filter cage 200 of the illustrated embodiment is attached at or near the forward-most end 106 b of the cover 106, and distant from the rear-most end 106 c of the cover 106. Thus arranged, and with reference to a longitudinal axis AA defined by the cover 106, the filter cage 200 is disposed between the fill opening 106 a and the forward-most end 106 b, and is located relatively closer to the forward-most end 106 b than to the fill opening 106 a. As discussed in further detail with regard to FIG. 5, the filter cage 200 may be positioned that a forward-most portion of the filter cage 200 is spaced apart from a forward most edge of the spout 114 a particular distance, or at least within a particular range of distances.

With particular reference now to FIG. 3, and continuing attention to FIGS. 1 and 2, further details are provided concerning the example filter cage 200 and the cover 106. In general, the filter cage 200 can be removably connected to the cover 106 by any suitable mechanism or structure so as to enable a user to periodically remove and replace the filter (see FIGS. 4 and 5) disposed inside the filter cage 200. For example, the filter cage 200 and the cover 106 can each include complementary structures configured to releasably engage the complementary structures of the other. Thus, in the particular example of FIG. 3, the filter cage 200 and the cover 106 are configured with a twist-lock type of configuration which enables a user to lock the filter cage 200 to, and unlock the filter cage 200 from, the cover 106 by rotating the filter cage about 90 degrees clockwise or counter-clockwise, as appropriate.

As shown in FIG. 3, the filter cage 200 includes a plurality of engagement elements 202 configured to interface with a corresponding engagement element 106 d of the cover 106. In more detail, the engagement elements 202 each include a ramp 204 configured to slidingly interface with a corresponding ramp 106 e of one of the engagement elements 106 d. As well, the engagement elements 106 d define an open-ended slot 106 f configured to removably receive the body of a corresponding engagement element 202. In operation, rotation of the filter cage 200 to an engaged position causes a cam action in which as the ramps 204 move up corresponding ramps 106 e, the filter cage 200 moves upward into the cover 106 until the body of each engagement element 202 has reached the limit of its travel within the corresponding slot 106 f, at which time the filter cage 200 is fully engaged with the cover 106. The user can remove the filter cage 200 from the cover 106 simply by rotating the filter cage 200 in the direction opposite the direction used to engage the filter cage 200 with the cover 106.

In at least some embodiments, the filter cage 200 and filter assembly 300 are configured and arranged such that when engaged with the cover 106, the fluid path from the filter assembly 300 to the cover 106 and spout 114 is closed, or substantially closed. In this configuration, unfiltered fluid from the reservoir 102 can only enter this fluid path by way of the filter assembly 300. Thus, little or no unfiltered fluid may be dispensed during a dispensing operation.

With continuing reference to FIG. 3, and directing attention now to FIG. 4 as well, further details are provided concerning the filter assembly 300. It should be noted that in at least some embodiments, the filter assembly 300 can be a filter assembly as disclosed in one or more of the ‘Related Applications’ noted herein, although the scope of the invention is not limited to those embodiments of a filter assembly.

As indicated in FIG. 4, the filter assembly 300 includes a filter core 302 about which is wrapped a filter medium 304, which can take the form of a laminate for example. A core cover 306 is also included that is configured to fit into the filter core 302 and control fluid flow out of the upper end of the filter core 302. Finally, a sealing element 308, such as an O-ring for example, is provided that seals the filter core 302 to the cover 106.

Finally, and as discussed in more detail below in connection with FIG. 5, it can be seen in FIG. 4 that the cover 106 and/or filter assembly 300 can be configured so that when the filter assembly 300 is attached to the cover 106, the filter assembly 300 is disposed at an angle relative to vertical. In the particular example of FIG. 4, the filter assembly 300 is tilted at an angle away from vertical in the range of about 0 degrees to about 30 degrees, although different angles and ranges can alternatively be employed, and the scope of the invention is not limited to any particular orientation of the filter assembly 300.

C. Example Filter Placement Configurations

Directing attention now to FIG. 5, details are provided concerning some example filter assembly and filter cage placement configurations with respect to a fluid container, such as the fluid container 100. For the purposes of illustration, filter cage 200 and filter assembly 300 are indicated in FIG. 5, although it should be appreciated that other filter cages and/or filter assemblies could alternatively be employed. In the example of FIG. 5, the filter cage 200 and the filter assembly 300 are shown fully engaged with the fluid container 100, particularly, the cover 106. As well, a longitudinal axis BB defined by the filter cage 200 is disposed at an angle away from vertical and/or may be parallel, or non-parallel, with respect to the wall 102 a of the fluid container.

In general, and as indicated in FIG. 5, the filter cage 200 can be located substantially closer to a front portion of the wall 102 a, that is, a portion of the wall 102 a located proximate the spout 114, than to a rear portion of the wall 102 a, that is, a portion of the wall 102 a located proximate the handle. As such, and disclosed in FIG. 5, at least a portion of the filter cage 200 may be disposed directly beneath the spout 114. Thus, for example, during a dispensing operation in which the fluid container 100 is generally horizontal, the filter cage 200 and filter assembly 300 may be located in a lower third of the reservoir 102.

As shown in FIG. 5, the filter cage 200 is located relatively close to the wall 102 a of the fluid container 100. The proximity of the filter cage 200 to the wall 102 a can be considered in terms of a gap ‘G’ that is cooperatively defined by the front edge of the spout 114 and the front edge of the filter cage 200. In at least some embodiments, the gap ‘G’ is in the range of about 2.0 mm to about 20 mm. In some particular embodiments, the size of the gap ‘G’ is relatively closer to 2.0 mm than to 20 mm. The width of the gap ‘G’ may be substantially the same along the length, or a majority of the length, of the gap ‘G.’ It will be appreciated that a desired spacing between the wall 102 a and the front edge of the filter cage 200 can be derived from a range of acceptable values of ‘G.’

In some embodiments, gap sizes outside of the aforementioned range may not produce good results. For example, a gap ‘G’ less than about 2.0 mm can result in scratches or scuffs to the reservoir 102 when the filter cage 200 is installed or removed. On the other hand, a gap ‘G’ greater than about 20 mm may be accompanied by relatively lower flow rates, an increase in the amount of unfiltered water dispensed, and/or a relatively large amount of unfiltered fluid remaining in the reservoir.

The size of the gap ‘G’ can be changed in a variety of ways. For example, a relatively larger gap ‘G’ may be achieved by using a filter cage 200 of relatively smaller diameter. Conversely, a relatively smaller gap ‘G’ may be achieved by using a filter cage 200 of relatively larger diameter. As another example, the cover 106 can be modified by changing the location and/or orientation of the portion of the cover 106 that interfaces with the filter cage 200. In this way, the location and/or orientation of the filter cage 200 and, accordingly, the size of the gap ‘G,’ can correspondingly be changed.

It will be appreciated from the present disclosure that determination of the size of the gap ‘G’ is a non-trivial exercise. Rather, this determination is the outcome of a complex analytical process that must take into account a variety of factors. As noted herein, such factors can include, but are not limited to, the geometry of the filter cage and/or filter assembly, the geometry of the reservoir wall, the geometry of the cover, an acceptable flow rate or range of flow rates, an acceptable amount of unfiltered fluid that can remain in the reservoir after a dispensing process, an acceptable value or range for the amount of fluid that must be filtered in connection with one or more dispensing processes, the hydrostatic head of fluid above the filter assembly during a dispensing operation, and any other factors disclosed or implied herein but not explicitly enumerated here.

As will be further evident from this disclosure, embodiments of the invention may provide a variety of advantages. For example, the fluid container can define a closed, or substantially closed, fluid pathway between a filter and a reservoir outlet. As another example, the fluid container can be configured to implement any one or more of reduction or minimization of the amount of unfiltered water left in the fluid container after a dispensing event, reduction or substantial elimination of bypass around the filter, and achievement of relatively higher flow rates based on hydrostatic pressure at the filter inlet.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

What is claimed is:
 1. A fluid pitcher container, comprising: a reservoir having a reservoir wall; a handle attached to the reservoir; a cover extending along a longitudinal axis from a first end to an opposed second end, the cover configured to engage the reservoir from the first end to the opposed second end, wherein the second end of the cover is rotatably connected to the handle; a spout disposed at the first end of the cover; and a filter cage configured to releasably engage the cover at a location adjacent the spout at the first end and opposite the second end of the cover adjacent the handle; wherein when the filter cage is fully engaged with the cover and the cover is engaged to the reservoir, a gap is defined between the reservoir wall at the first end and the filter cage, the gap having a range of about 2.0 mm to about 20 mm.
 2. The fluid pitcher container of claim 1, wherein a width of the gap is substantially the same along a majority of a length of the filter cage.
 3. The fluid pitcher container of claim 1, wherein the filter cage is substantially parallel to at least a portion of the reservoir wall at the first end.
 4. The fluid pitcher container of claim 1, wherein a longitudinal axis defined by the filter cage is disposed at an angle away from vertical when the fluid pitcher container is not tilted.
 5. The fluid pitcher container of claim 1, further comprising a filter disposed in the filter cage, wherein a fluid path extending from the reservoir through the filter to the spout is closed or substantially closed.
 6. The fluid pitcher container of claim 1, wherein the cover further includes a fill opening proximate a midpoint of the cover and spaced apart from the first end and the second end, and the filter cage is positioned between the spout and the fill opening adjacent the first end.
 7. The fluid pitcher container of claim 1, wherein the width of the gap is closer to 2 mm than to 20 mm.
 8. The fluid pitcher container of claim 1, wherein at least a portion of the filter cage is disposed directly beneath the spout and opposite the second end of the cover adjacent the handle.
 9. The fluid pitcher container of claim 6, further comprising a lid rotatably connected to the cover to cover the fill opening.
 10. The fluid pitcher container of claim 1, further comprising a filter disposed in the filter cage, the filter including a filter medium wrapped about a filter core and including a core cover configured to fit in the filter core to control fluid flow out of the filter core.
 11. The fluid pitcher container of claim 10, wherein the filter medium is in the form of a laminate, including a layer of activated carbon fiber positioned between two layers of non-woven material.
 12. The fluid pitcher container of claim 1, wherein the filter cage is secured to the cover by way of a twist-lock mechanism, wherein rotating the filter cage about 90° can lock or unlock the filter cage from the cover, wherein the twist-lock mechanism includes a first engagement element having a first ramp on the filter cage and a second engagement element having a second ramp on the cover, wherein the first and second ramps slidingly interface to move the filter cage upward into the cover.
 13. A fluid pitcher container, comprising: a reservoir having a reservoir wall; a handle attached to the reservoir; a cover extending along a longitudinal axis from a first end to a second end with a fill opening passing through the cover and positioned between the first end and the second end, the cover pivotably attached to the handle at the second end; a spout disposed at the first end of the cover; and a filter cage configured to releasably engage the cover at a location between the spout and the fill opening; wherein the fill opening is proximate a midpoint of the cover and spaced apart from the first and second ends.
 14. The fluid pitcher container of claim 13, further comprising a lid rotatably connected to the cover to cover the fill opening.
 15. The fluid pitcher container of claim 13, wherein the filter cage is substantially parallel to at least a portion of the reservoir wall.
 16. The fluid pitcher container of claim 13, wherein when the filter cage is fully engaged with the cover, a gap is defined between the reservoir wall and the filter cage, the gap having a range of between about 2 mm to about 20 mm.
 17. The fluid pitcher container of claim 13, wherein, during a dispensing operation in which the fluid pitcher container is oriented generally horizontally, the filter cage is located below a horizontal line passing at a height midway to the height of the reservoir while in a horizontal rotation.
 18. A fluid pitcher container, comprising: a reservoir having a reservoir wall; a handle attached to the reservoir; a cover rotatably connected to the handle at a first end and configured to engage the reservoir; a spout disposed at a second end of the cover opposite the first end; and a filter cage configured to releasably engage the cover at a location adjacent the spout, wherein when the filter cage is fully engaged with the cover, at least a portion of the filter cage is disposed directly beneath the spout and directly adjacent a front portion of the reservoir wall.
 19. The fluid pitcher container of claim 18, wherein a gap is defined between the front portion of the reservoir wall and the filter cage, the gap having a range of between about 2 mm to about 20 mm. 